Rear Window Replacement Utilityw/ Cargo Door
Tools Required
• | J 24402-A Glass
Sealant Remover (Cold Knife) |
• | J 39032 Stationary
Glass Removal Tool |
• | Urethane Adhesive Kit GM P/N 12346392 or Equivalent |
• | Isopropyl Alcohol or Equivalent |
• | Cartridge-type Caulking Gun |
• | Commercial-type Utility Knife |
Removal Procedure
Important: Before cutting out a window, apply a double layer of masking tape around
the perimeter of the painted surfaces and inner trim around the window.
- Remove the window garnish molding from the door frame. Refer to
Rear Door Trim Panel Replacement
in Body Rear
End.
Caution: When working with any type of glass or sheet metal with exposed or rough
edges, wear approved safety glasses and gloves in order to reduce
the chance of personal injury.
- Use safety
glasses and gloves.
- Disconnect the electrical
connector from the window defogger on the window, if equipped.
Important: Keep the cutting edge of the tool against the window. This will allow
the urethane adhesive to be separated from the window. Leave a base
of urethane on the pinchweld flange. The only suitable lubrication
is clear water.
- Using the J 24402-A
or J 39032
in order to remove the
window. Do this from inside the vehicle to protect the outer
surface of the paint.
- With the aid of an assistant,
remove the window from the opening.
Installation Procedure
- With the aid of an assistant, dry fit the window in the opening
in order to determine the correct way to position the window in the opening.
- Use masking tape in order to mark the location of the window
in the opening.
- Slit the masking tape at the top edge of the window.
- With the aid of assistant and using suction cups remove the window
from the opening.
- Place the window inside up on a clean, protected surface.
- Inspect for any of the following problems in order to help prevent
future breakage of the window:
- Inspect the following components for the causes of a broken window:
• | The flange of the window opening |
• | The window reveal molding |
- Inspect for any of the following problems in order to help prevent
future breakage of the window:
• | Hardened spot weld sealer |
• | Any other obstruction or irregularity in the pinchweld flange |
Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs
or replacements are required, the pinchweld flange must be refinished in order
to restore the bonding area strength. If paint repairs are required,
mask the flange bonding area prior to applying the color coat
in order to provide a clean primer only surface. Materials such
as BASF DE17®, DuPont 2610®, Sherwin-Williams
PSE 4600 and NP70® and Martin-Semour 5120
and 5130® products are approved for this
application.
- After repairing the opening as indicated, perform the following steps:
9.2. | Remove no more of the urethane adhesive from the pinchweld than
necessary in order to maintain the original shape. This will ensure
the proper clearance between the window and the pinchweld flange. |
| Important: Do not remove all traces of the adhesive. Remove all mounds or loose
pieces of urethane adhesive.
|
9.3. | If the original window is being reused remove all but a thin film of
the existing urethane adhesive from the window surface by using a clean
utility knife or razor blade scraper. |
9.4. | If the extended method is being used remove all but approximately
2 mm (3/64 in) of the existing bead of adhesive from the pinchweld
flange. |
9.5. | After repairing the opening, remove all traces of broken glass
from the outer cowl panel, seats, floor and defroster ducts. |
9.6. | Clean around the edge of the inside surface of the window with
a 50/50 mixture of isopropyl alcohol and water
by volume on a dampened lint free cloth. |
Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392
(Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification
GM3651G, to maintain original installation integrity. Failure to use the urethane
adhesive kit will result in poor retention of the window which may allow unrestrained
occupants to be ejected from the vehicle resulting in personal injury.
- Verify all
primers and urethane adhesive are within expiration dates.
Caution: Failure to prep the area prior to the application of primer
may cause insufficient bonding of urethane adhesive. Insufficient bonding
of urethane adhesive may allow unrestrained occupants to be ejected from
the vehicle resulting in personal injury.
Important: Do not apply the (black #3 primer to the existing bead of the
urethane adhesive. Apply only to nicks, scratches or the primed surfaces.
- Shake the pinchweld primer (black #3) for at least 1 minute.
- Use a new dauber to apply the primer to the surface of the pinchweld
flange.
- Allow the pinchweld primer to dry for approximately 10 minutes.
Important: Use care when applying prep (clear #1) on the window. This primer
dries almost instantly, and may stain the viewing area of the window if not
applied evenly.
- Use a new dauber in order to apply glass prep (clear #1) to the
area approximately 10-16 mm (3/8-5/8 in) around
the entire perimeter of the window inner surface.
- Apply a second coat of
the glass prep number (clear #1) to the same area of the glass.
- Wipe the glass primed area immediately with a clean lint free
cloth.
- Shake the glass primer
(black #2) for at least 1 minute.
The glass primer (black #2) is good up to 8 hours after
applying it to the glass. The primed surface of the glass must be kept clean.
- Use a new dauber in order to apply the glass primer (black #2)
to the same areas (2) that glass prep (clear #1)
was applied.
- Allow the glass primer to dry for approximately 10 minutes.
- If using the short method,
cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm
(1/4 in).
- If using the extended method, cut the applicator nozzle in order
to provide a bead of 12.7 mm (1/2 in) wide
and 12.7 mm (1/2 in ) high.
- Use a cartridge type caulking
gun to apply a smooth, continuous bead of urethane adhesive.
- When using the short method, apply the urethane adhesive to the
existing bead of urethane adhesive on the body.
- When using the extended
method, use the edge of the window or the inside edge of the reveal molding
as a guide for the nozzle in order to apply the urethane adhesive (1)
to the inner surface of the window (3).
If applying urethane adhesive to the inside edge of the window reveal
molding (1) use the window reveal molding as a guide for the
nozzle.
- With the aid of an assistant, use the suction cups in order to
install the window into the opening.
- Align the tape lines on the window and the body.
- Press the window firmly into place.
- Tape the window to the body in order to minimize movement until
the urethane adhesive cures.
- Clean any excess urethane
adhesive from the body.
Important: Do not direct a hard stream of high pressure water to the freshly applied
urethane adhesive.
- Use a soft spray of warm water in order to immediately water test the
window.
- Inspect the window for leaks.
- If any leaks are found, use a plastic paddle in order to apply
extra urethane adhesive at the leak point.
- Retest the window for leaks.
Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants
to be ejected from the vehicle resulting in personal injury.
• | For the moisture-curing type of urethane adhesive, allow a minimum
of 6 hours at 21°C (70°F) or greater and with at least 30 percent
relative humidity. Allow at least 24 hours for the complete curing
of the urethane adhesive. |
• | For the chemical-curing type of urethane adhesive, allow a minimum
of 1 hour . |
Do NOT physically disturb the repair area until after these minimum
times have elapsed.
- The following conditions must be maintained to properly cure the urethane:
34.1. | Partially lower a door window in order to prevent pressure buildups
when closing doors before the urethane adhesive cures. |
34.2. | Do not drive the vehicle until the urethane adhesive is cured.
Refer to the above curing times. |
34.3. | Do not use compressed air in order to dry the urethane adhesive. |
- Connect the electrical
connector to the window defogger on the window, if equipped.
- Install the window garnish molding to the door frame. Refer to
Rear Door Trim Panel Replacement
in Body Rear
End.
- Remove the protective coverings and tape from the vehicle and
headliner.
Rear Window Replacement Pickup
Tools Required
• | J 24402-A Glass
Sealant Remover (Cold Knife) |
• | Urethane Adhesive Kit GM P/N 12346392 or Equivalent |
• | Isopropyl Alcohol or Equivalent |
• | Cartridge-type Caulking Gun |
• | Commercial-type Utility Knife |
Removal Procedure
Important: Before cutting out a window, apply a double layer of masking tape around
the perimeter of the painted surfaces and inner trim around the window.
- Remove the window lower garnish molding. Refer to
Rear Window Lower Garnish Molding Replacement
in Interior Trim.
- Remove both rear seat headrests (extended cab). Refer to
Head Restraint Replacement
in Seats.
- Lower rear seat back.
Caution: When working with any type of glass or sheet metal with exposed or rough
edges, wear approved safety glasses and gloves in order to reduce
the chance of personal injury.
- Use safety
glasses and gloves.
- Using a sharp utility
knife, make a preliminary cut around the perimeter of the window. Cut as
close to edge of the window as possible.
Important: Keep the cutting edge of the tool against the window. This will allow
the urethane adhesive to be separated from the window.
Leave a base of urethane on the pinchweld flange.
The only suitable lubrication is clear water.
- Use the J 24402-A
or
the J 39040
in order
to cut the window from the pinchweld flange. Do this from inside
the vehicle in order to protect the outer paint
surface.
- Open the window, if equipped.
- With the aid of an assistant,
remove the window from the opening.
Installation Procedure
- With the aid of an assistant,
dry fit the window in the opening in order to determine the correct way to
position the window in the opening.
- Use masking tape (1)
in order to mark the location of the window in the opening.
- Slit the masking tape at the top edge of the window.
- With the aid of assistant and using suction cups remove the window
from the opening.
- Place the window inside up on a clean, protected surface.
- Inspect for any of the following problems in order to help prevent
future breakage of the window:
- Inspect the following components for the causes of a broken window:
• | The flange of the window opening |
• | The window reveal molding |
- Inspect for any of the following problems in order to help prevent
future breakage of the window:
• | Hardened spot weld sealer |
• | Any other obstruction or irregularity in the pinchweld flange |
Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs
or replacements are required, the pinchweld flange must be refinished in order
to restore the bonding area strength. If paint repairs are required,
mask the flange bonding area prior to applying the color coat
in order to provide a clean primer only surface. Materials
such as BASF DE17®, DuPont 2610®,
Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120
and 5130® products are approved for this application.
- After repairing the opening do the following.
- Inspect the condition of the window opening and the urethane
adhesive bead to determine which installation method should be used. Refer
to
Short Method Description
or
Extended Method Description
for
guidelines.
- Remove no more of the urethane adhesive from the pinchweld than
necessary in order to maintain the original shape. This will ensure the
proper clearance between the window and the pinchweld flange.
Important: Do not remove all traces of the adhesive. Remove all mounds or loose
pieces of urethane adhesive.
- If the original window is being reused remove all but a thin film of
the existing urethane adhesive from the window surface by using a clean
utility knife or razor blade scraper.
- If the extended method is being used remove all but approximately
2 mm (3/64 in) of the existing bead of urethane adhesive from
the pinchweld flange.
- Remove all traces of broken glass from the outer cowl panel, seats,
floor and defroster ducts.
- Clean around the edge of the inside surface of the window with
a 50/50 mixture of isopropyl alcohol and water by volume on a
dampened lint free cloth.
Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392
(Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification
GM3651G, to maintain original installation integrity. Failure to use the urethane
adhesive kit will result in poor retention of the window which may allow unrestrained
occupants to be ejected from the vehicle resulting in personal injury.
- Verify all
primers and urethane adhesive are within expiration dates.
Caution: Failure to prep the area prior to the application of primer
may cause insufficient bonding of urethane adhesive. Insufficient bonding
of urethane adhesive may allow unrestrained occupants to be ejected from
the vehicle resulting in personal injury.
Important: Do not apply the (black #3 primer to the existing bead of the
urethane adhesive. Apply only to nicks, scratches or the primed surfaces.
- Shake the pinchweld primer (black #3) for at least 1 minute.
Use a new dauber to apply the pinchweld primer (black #3) to
the surface (1) of the bonding area on the body only.
- Allow the primer to dry for approximately 10 minutes.
Important: Use care when applying prep (clear #1) in the window. This primer
dries almost instantly, and may stain the viewing area of the window if not
applied evenly.
- Use a new dauber in order to apply glass prep (clear #1) to the
area approximately 10-16 mm (3/8-5/8 in) around
the entire perimeter of the window inner surface.
- Apply a second coat of
the glass prep number (clear #1) to the same area of the glass.
- Wipe the glass primed area immediately with a clean lint free
cloth.
- Shake the glass primer
(black #2) for at least 1 minute.
- Use a new dauber in order to apply the glass primer (black #2)
to the same areas (2) that glass prep (clear #1)
was applied.
- The glass primer (black #2) is good up to 8 hours
after applying it to the glass. The primed surface of the glass must be kept
clean.
- Allow the glass primer to dry for approximately 10 minutes.
- If using the short method,
cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm
(1/4 in).
- If using the extended method, cut the applicator nozzle in order
to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm
(1/2 in ) high.
- Use a cartridge type caulking
gun to apply a smooth, continuous bead of urethane adhesive.
- When using the short method, apply the urethane adhesive to the
existing bead of urethane adhesive on the body.
- When using the extended
method, use the edge of the window or the inside edge of the reveal
molding as a guide for the nozzle in order to apply the urethane
adhesive (1) to the inner surface of the window (3).
If applying urethane adhesive to the inside edge of the window reveal
molding (1) use the window reveal molding as a guide for the
nozzle.
- With the aid of an assistant,
install the window to the opening.
- Align the tape lines on the window and the body.
- Press the window firmly into place.
- Tape the window to the body in order to minimize movement until
the urethane adhesive cures.
- Clean any excess urethane
adhesive from the body.
Important: Do not direct a hard stream of high pressure water to the freshly applied
urethane adhesive.
- Use a soft spray of warm water in order to immediately water test the
window.
- Inspect the window for leaks.
- If any leaks are found, use a plastic paddle in order to apply
extra urethane adhesive at the leak point.
- Retest the window for leaks.
Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants
to be ejected from the vehicle resulting in personal injury.
• | For the moisture-curing type of urethane adhesive, allow a minimum
of 6 hours at 21°C (70°F) or greater and with at least 30 percent
relative humidity. Allow at least 24 hours for the complete curing
of the urethane adhesive. |
• | For the chemical-curing type of urethane adhesive, allow a minimum
of 1 hour . |
Do NOT physically disturb the repair area until after these minimum
times have elapsed.
- The following conditions must be maintained to properly cure the urethane
adhesive:
40.1. | Partially lower a door window in order to prevent pressure buildups
when closing doors before the urethane adhesive cures. |
40.2. | Do not drive the vehicle until the urethane adhesive is cured.
Refer to the above curing times. |
40.3. | Do not use compressed air in order to dry the urethane adhesive. |
- Install the window lower garnish molding. Refer to
Rear Window Lower Garnish Molding Replacement
in Interior
Trim.
- Install both rear seat headrests (extended cab). Refer to
Head Restraint Replacement
in Seats.
- Raise the rear seat back.
- Remove the masking tape from the area around the window in order
to protect the painted surfaces from damage and to protect the headliner.